1. Overview… Let’s have a conversation together
Markets, Applications
ASME Code Requirements
Products – The demo’s at the back of the room
Features/Benefits & Reliability
A rep’s perspective

2. INTRODUCTION What is a “Level-Trac” ?
A multi-point, conductivity based, remote level indicator for boiler water level monitoring and water detection.
REMOTE DISPLAY
CONTROL UNIT
PROBE CHAMBER

3. What are Level-Trac systems used for?
INTRODUCTION
What are Level-Trac systems used for?
- Satisfy Boiler Code as Remote Level Indicator
- Monitoring Water Level
- Discrete system, independent of DCS
- High / Low switch points
- Turbine water induction protection

4. WHO IS OUT THERE?
#1 – CLARK-RELIANCE – “Eye-Hye” [Remote] Probe Columns, “SimpliPort” Bi-Colored Gauges [direct], “FG” Series Glass Gauges [direct]
#2 – YARWAY (Direct Glass, Incl. ColorPort, and Indirect Probe-type Aquarian. Note: prior to TYCO purchase?)
#3 – SOLARTRON (Indirect Probe-type – “Hydrastep”)
#4 – FOSSIL (Indirect Probe-type also “Aquarian”)
#5 – DIAMOND (Direct – “Duraport” [note: Diamond does not make a Flat Glass Gage, only bi-color ported] Indirect – “Merli” Probe-type)
#6 – PENBERTHY-GILCO (Direct & Indirect, prior to Tyco purchase? Also note that Penberthy was offering replacement probes & parts)

5. Hydrastep / Emerson WHO IS OUT THERE?
- Quest-Tec visited a power station
with Hydrastep RLI’s in 1QT18.
- The plant reported that Emerson is no longer
offering spare circuit boards for the 2468 model.

6. Find out who/what they currently use?
CONVERSATIONS WITH PROSPECTS
Find out who/what they currently use?
Is it working satisfactorily? Do your operators like it?
What do your maintenance techs like or not like about it?
How often do you replace parts and/or repair the gage or column?
At what expense of parts and time?
Who provides your parts and service?

7. MARKETS
Power Plants
Pulp & Paper
Refineries
Chemical Plants
Waste to Heat
Industrial Manufacturing
Hospitals, Universities

8. Boiler Types, permanent capital fixtures in your patch, worth frequenting
Pressure or Power – Good Market, better in past
Recovery, fuel from a process by-product.
Refuse, Trash, smells like it sounds
Package – Small boilers, tube glass or prismatic
HRSG’s – If there were one single place to advise you to visit, this is it . This EPA friendly energy source is tough on instruments due to thermal cycling, our products fair best.

9. APPLICATIONS
Boiler Drums
Heater Drums
Deaerator
Condensers, Hotwell’s - steam turbine exhaust
Turbine Water Induction Protection
Motive Steam Mains
Reheat & Superheat Line Drip Pots
Drain Pots Located down stream of attemperators

10. Types of Boiler Drum Level Direct & Indirect Instruments
Gage Glass – Direct Reading
- Gage Glass or “Sight Glass”
Remote Level Indicator – Indirect Reading
- DP Cell
- GWR
- Magnetic Level Gauge
- Conductivity Probe

11. Boiler Code Requirements
Remote Level Indicator – Indirect Reading
- DP Cell
- GWR
- Magnetic Level Gauge
- Conductivity Probe
ASME Boiler Code
- Independent System
- Continuously Measure, Transmit & Display
- Viewable to Operators at All Times
- Visual Display in Control Room

12. ASME SEC. I CODE BOILER GAUGES & VALVES 600 MAWP BOILER
REMOTE
INDICATOR
PROBE
SYSTEM
SIGHT
GLASS
SIGHT
GLASS
600 MAWP BOILER A
600 MAWP BOILER B
GWR DP
CELL DP
CELL DP
CELL DP
CELL DP
CELL DP
CELL
REMOTE
INDICATOR
CONTROL
CONTROL
CONTROL
CONTROL
CONTROL
REMOTE
INDICATOR

13. CODE COMPLIANT SYSTEM Field Measurements Level-Trac Water Column- 1
Level-Trac Electronics
Level-Trac Water Column- 2
Steam-Trac Gage Glass
Field Measurements

14. REMOTE LEVEL INDICATOR
REMOTE LEVEL INDICATORS
SYSTEM SUMMARY
PROBE COLUMN
CONTROL UNIT
REMOTE LEVEL INDICATOR
Wiring supplied by installers
▀ Control Room
DRUM C-C
PROBE SPAN
115 VAC Power Supply
Remote Indicator 1
High temp cable option
provided By Quest-Tec
Remote Indicator 2
4 – 20 mA Output
4 Independent Relays
▀ Local indication at the boiler drum
▀ Remote indication for the control room
▀ (4) Relays for the switch points L/LL/H/HH
▀ 4-20mA Output

15. REMOTE LEVEL INDICATORS APPLICATION ADVANTAGES
▀ Multiple sensor element array
- No single point of failure within sensing element
▀ Non-Mechanical level sensing
- Higher reliability compared to magnetic float
▀ Critical electronics distant to process heat (5’ to 20’ typ.)
- Unlike top head mount GWR or MLI switches
- Control unit mounted for ease of access and viewing
▀ Serviceable Components
- Individual items can be replaced
▀ Rugged design specifically for continuous high heat
- LT-500: 550 F / LT-501 & LT-502: 1,100 F

16. REMOTE LEVEL INDICATORS QUEST-TEC DESIGN, WHY US?
LT-500 & LT-501 CHAMBER
QTS
OTHER
▀ Deep thread engagement
- Double boss extrusion
▀ Coarse thread pitch
- Minimize galling issues
▀ Encapsulated gasket
- Field friendly – no over-torque concern
- Controlled gasket compression
▀ Shallow thread engagement
- Machined pipe wall
▀ Fine thread pitch
- Prone to galling issues
▀ Sandwiched gasket
- Weak gasket seal

17. Extruded A-105 Column Type 800 Probe Spiral Wound Probe Gasket
PROBE CHAMBER SUMMARY
1,000 PSI WSP LT-500
2,000 PSI WSP
LT-501
3,000 PSI WSP
LT-502
Extruded A-105 Column
Type 800 Probe
Spiral Wound Probe Gasket
Extruded A-105 Column
Type 810 Probe
Spiral Wound Probe Gasket
STD Pipe A ” Sch.160
Type 820 Probe
Swage Probe Seal

18. REMOTE LEVEL INDICATORS CONTROL UNITS
LT-220
▀ Up to 14 Probe Channels
▀ Dual Power Supply
▀ Door Mounted LED Display
▀ NEMA 4X FRP Enclosure
▀ 4, 8A DPDT Relays For L/LL/H/HH
HP/IP/LP Boilers
Heaters, Feedwater Tanks
LT-210
▀ Up to 12 Probe Channels
▀ Single Power Supply
▀ Door Mounted LED Display
▀ NEMA 4X FRP Enclosure
▀ 4, 8A DPDT Relays For L/LL/H/HH
HP/IP/LP Boilers
Heaters, Feedwater Tanks
LT-310
▀ Up to 6 Probe Channels
▀ Single Power Supply
▀ Door Mounted LED Display
▀ NEMA 4X FRP Enclosure
▀ 6, 8A DPDT Relays, 1 Per Channel
Drain Pots, Water Detection
Turbine Water Induction Protection

19. REMOTE LEVEL INDICATORS WHAT DO WE MEAN BY CHANNELS?
- One Probe
- One Circuit Through Control Unit
- One Indicator Light at Each Remote

20. REMOTE LEVEL INDICATORS TEST BUTTONS, CURCUIT CHECK
▀ Press and Hold the Green Test Button
All LEDS Green: Circuits Good
All LEDS NOT Green: Replace Discriminator PCB
▀ Press and Hold the Red Test Button
All LEDS Red: Circuits Good
All LEDS NOT Red: Replace Discriminator PCB
When either Test Button is pressed, all Relays return to normal, non-alarm/trip state
LT-310 has a slide switch that activates the test button, when test switch is “On”, SF will be indicated.

21. WATER COLUMN CODE REQUIREMENTS
PROBE CHAMBER vs. WATER COLUMN
WATER COLUMN CODE REQUIREMENTS
Minimum 1” Water/Steam Connections
3/4“ Minimum Drain Connection
SIGHT GLASS WITH WATER COLUMN
WATER COLUMN PROBE CHAMBER COMBINATION
RLI PROBE CHAMBER

22. HIGH TEMP STEEL EXPERIENCE SUMMARY
WATER DETECTION
HIGH TEMP STEEL EXPERIENCE
SUMMARY
Job References:
▀ Guadalupe Power SA-335 P22
▀ Lakeside II SA-335 P11
▀ Termozulia III SA-335 P91
▀ Parnaiba SA-335 P91
▀ Cane Run SA-335 P22
▀ Sugar Creek SA-335 P91
▀ Panda Liberty SA-335 P22
▀ Panda Patriot SA-335 P22

23. WATER DETECTION
HIGH TEMP STEEL EXPERIENCE
SUMMARY

24. POST WELD HEAT TREATMENT SUMMARY
CAPABILITIES
POST WELD HEAT TREATMENT
SUMMARY
Heat Treatment
▀ In-House Capability
▀ Postweld heat treatment (PWHT) is a method for reducing and
redistributing the residual stresses in the material that have been
introduced by welding. 
▀ P91 Welding
Superheater Outlet

25. PROBE COLUMN SYSTEMS

26. ELECTRONICS AND WATER COLUMNS
Transmits signal to column
Interprets signal from probes
Provides alarm & Trip Contacts
Settling chamber to mount the probes
NWL

27. Magne Trac or Level Trac
Why one over the other
    - If the float ever gets stuck, the instrument still indicates level based on stuck float, regardless of actual level variation.
    - Magnetic fines/particles will slowly build up on the float where the magnet is located.
    - The Level-Trac sensors are multi-point, whereas a magnetic gage has a single sensor, the mechanical magnetic float.
With Level-Trac, one sensor failure cannot disable entire system.
    - Level-Trac LT-210 Electronics are mounted completely away from process heat.
The local control box that drives the probes includes a LED indicator panel. Each probe has a red/green LED,
green is the water level.

28. Questions?
Recap

30. Channel Partner Testimony
Rick Barnes, Swansonflo, experience selling Level Trac against Clark Reliance

31. Typical Column Installation Reducing temperature/density error
Piping slopes 1:50
Insulation, all but 18” of piping at drum

32. CONTROL UNIT FEATURE COMPARISON
Model
LT-310
LT-210
LT-220
Maximum Channels 6 12 14
Power Supply
Switch VAC
Dual
Single
4-20 mA No
Yes
Sensitivity
.5, 1 & 1,5 Mmho
Sequence Logic
Programmable Relays
6 + Fault
4 + Fault
4, + Fault
Ch. Normal State
Programmable
Fixed, 1-8 Wet
List Price
$3,627
$4,876
$5,320

33. CABLE REQUIREMENT PROBES TO CONTROL UNIT
NWL
OPTION PROVIDED BY QUEST-TEC
20 AWG, NICKEL PLATED COPPER, PFA INSULATED
1 CONDUCTOR PER WET CHANNEL
2 CONDUCTORS PER DRY CHANNEL
2 COMMON/GROUND CONDUCTORS

34. CONTROL UNIT TO REMOTE – SERIAL OPTION
CABLE REQUIREMENTS
CONTROL UNIT TO REMOTE – SERIAL OPTION
NWL
PROVIDED BY INSTALLERS
18-20 AWG Tinned Copper
6 Twisted Pair

35. Find out who/what they currently use?
CONVERSATIONS WITH PROSPECTS
Find out who/what they currently use?
Is it working satisfactorily? Do your operators like it?
What do your maintenance techs like or not like about it?
How often do you replace parts and/or repair the gage or column?
At what expense of parts and time?
Who provides your parts and service?

36. OPPORTUNITIES
Heater Level and Trips

37. OPPORTUNITIES
Leaks & Explodes

38. What is a Guided Wave? GUIDED WAVE Microwave Burst Tracks a SS Rod
Time Domain Reflectometer (TDR)

39. ROUGHING CONSIDERATIONS
Probes have a significant upper blind spot
Need 28” for Dynamic Vapor Compensation
Lower Blind spot
Quest-Tec Recommends allowing 6”
The last couple of inches have reduced accuracy.

40. XXX PROBE TYPES Bare Probe Coax Probe
Wave will ignore irregularities on the column wall.
Cost is nominal for the benefit.

42. DRUM C-C & MEASURING RANGE: 27.00”
HEAD UNIT: ”
REMOVEAL CLEARANCE:
GWR OAL + 1-2”
UPPER DEAD ZONE: ”
GWR OAL:
75.00”
DRUM C-C & MEASURING RANGE: ”

43. PROBE LENGTHS
Probes Lengths on Steam Drums are relatively short
Probe length cost is nominal
Quest-Tec Recommends a probe length long enough to measure the full range between column centers – Even with a reduced range requirement

44. MAWP RATINGS GUIDE Pipe Schedule 3” SCH 160 SA-106C Chamber
Chamber ° F
1/16” Corrosion Allowance
3” SCH 80 SA-106C Chamber
Chamber ° F
Flange Rating – 316L SS
2500# ° F
1500# ° F
900# ° F
600# ° F
300# ° F
We strongly recommend specifying Weld Neck Flanges for the top of the Bypass at all pressures.

45. Display – Discrete, Continuous Display is Required
CONTROL UNIT CONSIDERATIONS
16-30 VDC to Generate Loop
Independent of DCS
Display – Discrete, Continuous Display is Required
Quantity of Remote Displays, Location
Local Display
Quantity of Points, 10, 14, 18, More Coming
Display Calibration – Faceplate Marking
Display Signal Transmission-RS485 Standard
Fiber Optic Option
Multiplexer Option HP, IP and LP on same Cable
Wireless Option Recommended as Auxiliary only

46. BASIC CODE REQUIREMENT

47. ≤ 400 PSI – At least One Gage Glass >400 PSI – Two Gage Glasses or
BASIC CODE REQUIREMENT: CONDENSED
In A Nut Shell:
≤ 400 PSI – At least One Gage Glass
>400 PSI – Two Gage Glasses or
Two Independent Remote Level Gages, and
One Gage Glass, which may be isolated

48. BASIC CODE REQUIREMENT
More Detailed, Often missed, Code Requirements

49. Quest-Tec Solutions Earning our Name

50. Fiber Optic Serial Transmission
Problem: End user required the serial signal to be transmitted from the LT-210 Control Unit to the control room LTI via fiber optic cable.

51. Fiber Optic Serial Transmission
Quest-Tec Solution: Designed two PCBs to carry, power, encode and transmit the RS485 remote signal display via fiber optic cable and decode signal and power at the control room mounted remote display.

52. Fiber Optic Serial Transmission
From Control Unit to Remote Display
ST Fiber Optic Connectors
Multimode 62.5/125 Cable
Rated to 6500 Feet

53. Multiplexer Fiber Optic Signal Transmission
Problem: End user wanted to transmit signal from HP, IP and LP drums unit to the control room remote displays… using a single fiber optic cable from each unit.

54. Guided Wave Radar
Problem: User wanted to replace probe column with Guided Wave Radar and use the probe column remote displays already mounted in the control room.

55. Guided Wave Radar
Quest-Tec Solution: Develop a PCB that would accept three programs to convert an analog 4-20 mA signal into a stepped RS485 signal to drive remote displays in the control room.

57. Group Exercises

58. GROUP EXCERCISES 2. Questtec Level Trac System
Application: 900 PSI Design, operating at 675 PSI
21”Centers
Outdoor Installation
Questions:
How many probes?
What pressure class of column?
How many probes do you recommend?
What is the relative position of the indication range
relative to the vessel connections?
Where is normal water level?
Vessel Connections?
How many remote indicators needed?
Control room, operating floor, on the control unit?
What size indicator is best for the control room panel?
Do they require any added control unit features?
(4-20 mA output second power supply)
What about spare parts? (probes or level sensing modules?
What about SureStart Service?

59. Typical Water Conductivities

60. LT-100 SERIES LIKE A CR Channels: 1 to 12
Independent relay modules, switches
Alarm contacts, 2 DPDT per channel

61. What will happen? Indicate water or steam?
OXIDES ON PROBE CERAMICS
What will happen? Indicate water or steam?

62. BASIC STEAM CYCLE

63. Package Boiler; Wabash & Indeck
Design features: Shop-assembled (package), which can be shipped by rail, truck or barge; gas-tight furnace, uses membrane construction for pressure firing; drainable superheater.
Capacity: 10,000 to 260,000 lbs./h
Steam pressure: To 1250 psig.
Steam temperature: To 850F.
Fuels: Oil (#2 through #6), natural gas

64. PROCESS RECOVERY BOILER
Design features: A chemical and heat recovery boiler for the pulp and paper industry; concentrated black liquor and combustion air are introduced into the furnace where heat is recovered as steam for electricity generation and process heating, and the inorganic portion of the black liquor is recovered as sodium compounds.
Liquor processing capacity: To 10,000,000 lbs./day (4500 t/day) dry solids.
Steam pressure: To 1850 psi
Steam temperature: To 950F
Fuel: Pulp mill liquor.
Auxiliary fuels: Natural gas and/or oil.

65. WASTE TO ENERGY
Design features: A Power Boiler with one- or two-drum designs; membrane wall construction with lower furnace.
Capacity: Up to 350,000 lbs./h (44.1 kg/s) steam flow; 100 to 1000 t/day of refuse.
Steam pressure: To 1800 psig (12.4 MPa) design.
Steam temperature: To 930F (499C).
Fuels: As-received, unprocessed municipal solid waste (MSW) and refuse-derived fuel (RDF) for new boilers; and RDF for retrofit applications; auxiliary gas and oil.

66. SUPERCRITICAL
Design features: A once-through boiler for supercritical applications, usually applied to systems with a capacity of 400 MW or larger; the design features a water-cooled dry-bottom furnace, superheater, reheater, economizer, and air heater components designed for both base load and full boiler variable pressure load cycling operation as well as on/off cycling operation.
Capacity, steam output: 2,000,000 to 10,000,000 lbs./h .
Operating pressure: psi.
Superheater steam temperatures: 1100⁰F .
Fuel: Pulverized coal.
No Boiler Drum, but TWIP Application

67. HRSG MSG - Module Steam Generators GTs from 20–70 MW, ST’s add more
1, 2, or 3 pressure levels. HP, IP & LP drums
1800, 850, 150psig Drums

68. HRSG w/COAL GASIFICATION

69. GWR - 5,8GHz signal down rod, bounce off DK’s
BOILER DRUM LEVEL INDIRECT INSTRUMENTS
DP Cell - calibrated instrument, pulse lines, temp compensated, inexpensive.
GWR - 5,8GHz signal down rod, bounce off DK’s
Magnetic Gauges- Good, but limited to 900psi per PG12
Probe Columns